Operating method and device for operating automated container quay cranes

ABSTRACT

An operating method for container quay cranes used to load and unload container ships by means of a PC with a monitor in a crane driver&#39;s cabin. The operating method is carried out by means of a touchscreen and enables the crane to reach its target according to specification in a fully or partially automatic manner.

SPECIFICATION

[0001] It appears to be impossible for the foreseeable future to replace a crane operator of container quay cranes with an automatic control. Today's container quay cranes are therefore operated in a semi-automatic fashion. Such semi-automatic operation has been successfully implemented.

[0002] However, the loading/unloading capability of these cranes lags behind expectations. The reason for this is that the majority of the crane operators have difficulties operating the automatic functions. What is lacking so far is a suitable man-machine interface which optimizes the interaction between the crane operator and the automatic control, as well as a corresponding operating method.

[0003] Thus far, various switches, pushbuttons and indicator lamps have been provided in the consoles of the crane operator's seat for operating the automatic control. However, these simple means give the crane operator insufficient information about the operating state of the automatic control, about the targets to be reached next by the automatic control, about error or warning messages, and/or about other operating states of the automatic control. In addition, these simple means limit a possible intervention in the automatic control.

[0004] The invention solves the aforedescribed technical problem in the following manner:

[0005] a) All operating and display elements are effectively combined on a touch screen. The touch screen is located on the right side next to and within reach of the crane operator's seat. This eliminates the operating knobs, pushbuttons and indicator lamps which were hitherto distributed in an often confusing and non-standard manner across the console of the crane operator's seat.

[0006] b) All essential control commands transmitted to the automatic control are entered on the touch screen by touching touch sensors.

[0007] c) All important information received from the automatic control are displayed on the touch screen.

[0008] d) A computer is associated with the touch screen. The computer processes the signals for display to the crane operator in ergonomic form.

[0009] e) The same computer also computes the target parameters for the automatic travel. Conventional solutions have so far left this task to the crane control, which resulted in many different non-standard solutions beset with errors.

[0010] The ergonomically constructed touch screen operator interface allows the crane operator, on one hand, to optimally observe the actions of the automatic control and, if necessary, to easily and safely intervene. On the other hand, the MMI touch screen can also provide the crane operator with instructions in the form of visual and optionally acoustic messages. This optimizes the exchange between automatic and manual operation.

[0011] According to the invention, crane operators which are frequently assigned to the different cranes with a different automation system, need no longer review an operating manual for the automatic operation before operating an automatic crane. Crane operators do not like and therefore frequently avoid reviewing operating instructions, relying on their memory instead. This can lead to mistakes.

[0012] How is a process of the invention performed?

[0013] When starting work on the crane, the crane operator turns on the touch screen. He then sees on the touch screen the image according to FIG. 1.

[0014] Color Selection White background Messages (text, numbers) Orange background Touch field, function not activated Green background Touch field, function activated Light blue Target indication Gray Crane outline Red End positions Purple Ship outline Yellow Message bar

[0015] Advantageously, a dark blue background is selected to enhance visibility. Visualization by selecting suitable colors is important since the high workload can cause a significant decrease in the mental concentration of the crane operator during a shift. A blue background color is particularly advantageous for the following reasons:

[0016] it prevents glare from the touch screen to the crane operator at night

[0017] it highlights the display fields and the operating button

[0018] Operating Mode

[0019] 1. The Crane Operator Starts Work With the Help of a Basic Setup Page.

[0020] Initially, the crane operator has to enter the basic settings for the automatic operation with the following operating steps:

[0021] 1.1 Setting the Main Operating Mode

[0022] The crane operator can switch the automatic operation on and off by using a switch which for safety reasons is the only operating component that is not located on the touch screen. The selection by the external switch is indicated on the touch screen in the uppermost row of FIG. 1 by a color change of the corresponding display field to green.

[0023] 1.2 Selecting the Operating Mode

[0024] The crane operator has hereby 3 possibilities:

[0025] Switching between fully automatic travel (in particular for bridging the large distance between land side and water side without introducing oscillations) and conventional operation (typically for fine-positioning of the load above the target, in particular on the ship).

[0026] Switching between automatic operation (again for overcoming the large distance) and manual operation with, i.e. for controlling the speed of the load (also for fine positioning of the load).

[0027] Function “Calming Oscillations” (arresting and positioning the load on the target after previous operation without oscillation control)

[0028] 1.3 Loading/unloading Mode

[0029] Vertically/cyclically Unloading or loading the container always in the same row on the ship

[0030] Horizontally Removing or stacking the containers layer-by-layer

[0031] 1.4 Intermediate Stop

[0032] When selecting the function Intermediate Stop, the containers are not directly transported to the corresponding target by the automatic control, but are first brought to rest at an intermediate stop position. This intermediate stop position is located on the land side below the crane. There, either the custom seal of the container is checked and/or the automatic twist locks are inserted in or removed from the bottom of the containers. After these task have been completed, the automatic control directs the container to the actual target.

[0033] 1.5 Number of Rows in the Bay

[0034] Here, the crane operator informs the automatic control of the number of rows of containers that are located in the ship's bay to be processed. The crane operator can increase or decrease the number of rows by using pushbuttons labeled “More” or “Less”. The display field located between the two pushbuttons indicates the number of rows previously set by the crane operator.

[0035] 1.6 Ship's Bow

[0036] The crane operator can indicate to the automatic control if the bow of the ship in front of him is located to the left or to the right of his position. The automatic control can use this information together with the information about the number of rows in the bay to insert the correct numbering of the container positions on the ship into the image depicted in FIG. 2. Further details can be found in the description of FIG. 2.

[0037] 1.7 Training Operation

[0038] When selecting the mode Training Operation, the crane operator can simulate to the automatic control by using a suitable pushbutton that a container was unloaded or received on the ship or the land side. It is the goal to allow switching of the target between ship side and land side even if no ship, on which container can be loaded or unloaded, is currently present. This functionality is necessary, since crane operators have to first train without a ship before beginning with the loading/unloading operation.

[0039] After completing the basic settings, the crane operator touches the button “To Page Automatic Operation” in the lower right part of FIG. 1, thereby arriving at the actual operating page depicted in FIG. 2.

[0040] 2. Page “Automatic Operation”

[0041] The crane operator keeps the page “Automatic Operation” permanently switched on when working on the ship. Changing to another page may distract the crane operator from his task, potentially leading to dangerous situations. For this reason, all relevant information and operating elements are included on the page “Automatic Operation” in ergonomic form.

[0042] The displayed image is essentially divided into three parts.

[0043] The water side (ship side) of the crane is located in the upper half of the image (above the yellow message bar).

[0044] The land side of the crane is depicted in the lower right half of the image.

[0045] Those operating data, which the crane operator has to monitor continuously, are depicted in the lower left section of the displayed image.

[0046] 2.1 The Water Side

[0047] 2.1.1 Crane Frame

[0048] The crane frame and—in the lower right corner—the quay edge are depicted in a gray color.

[0049] 2.1.2 Travel Direction of the Crab and Lifting Assembly

[0050] The white triangles in the crane frame represent arrow heads, which change to a green color in the direction in which the crane crab moves. The same applies to the arrow heads in the vertical crane leg when the load moves in the direction Raising or Lowering.

[0051] 2.1.3 Limit Switch

[0052] The color of the small white rectangles in front of the arrow heads changes to red when the crab and/or the lifting gear reaches the corresponding limit switch.

[0053] 2.1.4 Container Positions and Target Settings

[0054] The cross section of the ship is schematically indicated below the water-side crane jib. The container positions on or in the ship are depicted by numbered rectangular fields which represent the container receiving shafts below deck or the uppermost row of the containers loaded on deck.

[0055] The containers located below have been deliberately omitted, since they are irrelevant for the crane operator's operations. Displaying redundant information would distract the crane operator and hence impede the safety of the operation.

[0056] The number of rectangles corresponds to the number of rows in the bay entered by the crane operator under “Number of Rows in the Bay” when entering the basic settings.

[0057] A display field with a white background is located in the center of the rectangles and shows the number of the row according to an international standard. Rows on the starboard side of the ship are indicated with odd numbers in ascending order from the center of the ship to the outside. Rows on the port side of the ship are indicated with even numbers in ascending order from the center of the ship to the outside. If the ship has an odd number of rows, then the center rows has the number 0. Conversely, if the ship has an even number of rows, then the row 0 is omitted. The computer associated with the touch screen enters the numbers in the display fields of the rectangles depending on the number of rows in the bay and the particular situation, i.e., if the bow of the ship is positioned to the right, i.e. the starboard side is near the quay edge, and vice versa. This provides the crane operator with a direct correlation between the load manifest and the visualization on the touch screen.

[0058] Target Definition

[0059] The container rectangles also indicate to the crane operator the target that the automatic control is traveling to next. The border around the number field inside the rectangles then changes its color from gray to light blue, if the automatic control has determined that this row is to be the target for the automatic travel towards the ship side. The interior of the indicator field of the row number can also be colored light blue. This change in color indicates the last target to which the automatic control has traveled. This provides the crane operator with a point of reference between the previous target and the next target during automatic travel.

[0060] Change of Targets

[0061] The computer associated with the touch screen computes the next target depending if horizontal or vertical loading/unloading has been selected or if the ship is unloaded or loaded. In vertical operation, the target will be identical to the target in the last operation. In horizontal operation, one moves by one row farther towards the land side than in the previous operation. In horizontal loading, the next target is one row farther towards the water side than in the previous operation.

[0062] If the crane operator wants to change the target, he can use the touch button labeled “+” or “−”. When activating the “+” button, the target jumps by one row farther towards the water side. When the “−” button is activated, the target jumps by one row farther towards the land side. The target can be shifted by several rows by pressing the button several times. The light blue border around the number field then jumps to the newly defined field. This gives the crane operator full control of the set target (see FIG. 3).

[0063] 2.1.5 Target Position Lead

[0064] In the upper right corner, the touch button “Lead LS” (Lead Land Side) is located.

[0065] In a horizontal loading/unloading operation, the crane operator frequently does not want the automatic control to not move the load directly to the target position located exactly above the intended container row, but wants the load to come to rest approximately half a meter closer to the land side (coming to rest is intended to indicate being suspended above the target, without swaying or oscillating). This enables the crane operator to conveniently lean the load softly against the adjacent container—this time in manual operation. If the automatic control were to move the load directly above the target, then the crane operator would have to first manually move the load a small distance towards the land side, then lower the load, and then again manually lean the load against the adjacent container towards the water side. This is necessary because the load typically performs a more or less severe skew oscillation (rotation oscillation about the vertical axis), so that there is a danger that, when the load is lowered, one corner bumps against the neighboring container. (Activation of the function see FIG. 4)

[0066] Conversely, a touch button “Lead WS” (Lead Water Side) is provided in the upper left region of the image when the containers are intended to lean against the neighboring container from the water side.

[0067] 2.1.6 Target Jumps to the Water Side or Land Side end of the Ship

[0068] During horizontal loading and unloading operation, it occurs regularly that the loading and/or unloading operation on the land side or water side edge of the ship should be continued. For this reason, two additional touch buttons “Towards LS” (towards the land side) and “Towards WS” (towards the water side) are displayed for the basic settings according to FIG. 1 on the image shown in FIG. 2 when selecting the horizontal loading/unloading operation. The crane operator can then initiate a target jump to either the container row closest to the land side or to the container row located farthest to the water side.

[0069] 2.1.7 Teach Function

[0070] A large touch button “input target height ship” which has two Teach functions is located in the center of the container rectangles.

[0071] 2.1.7.1 Input Target Height Ship

[0072] At the beginning of the operation, the crane operator moves the load above the ship to the desired height and pushes the above-referenced touch button. This height is then assumed to be the target height for the subsequent automatic travel. The height can be reset for all additional travel by again pushing this button.

[0073] 2.1.7.2 Input Container Row

[0074] After inputting the target height, the text on the touch button changes to “Input Actual Container Row.” This operation occurs only during the first travel to the ship. The automatic control computes the most likely row based on the actual geometric data which corresponds to the actual position and indicates the result by changing the color of the corresponding rectangles to yellow. However, if the automatic has miscalculated this first indicated row, then the crane operator can correct this by pushing the button “+” or “−” and confirm the result by pressing the touch button (see FIG. 5). For all subsequent travel, the touch button displays again the text “Input Target Height Ship.” It this way, the crane operator can correct the target height above the ship for each travel, if desired.

[0075] 2.1.8 Simulation and Display “Unlocked-Locked”

[0076] The touch button, indicated in the image of FIG. 2 in green with the text “Unlocked” is only displayed if “Training Operation” was selected in FIG. 1. This function simulates to the automatic control that a container is attached or detached, i.e., locked and unlocked. The automatic control then switches the targets between land side and water side. “Unlocked” is typically indicated by a color change to green, whereas the locked state is indicated by a color change to red. Accordingly, the touch button takes on either a green or a red color. By touching the button, the state changes from Locked to Unlocked and vice versa (see FIG. 6).

[0077] 2.2 Land Side

[0078] 2.2.1 Travel Direction, Limit Switch, Crab Position

[0079] In the image depicted in FIG. 2, the land side of the crane is indicated in the lower right quarter of the image. The crane frame as well as the quay is again schematically indicated in gray. The touch button for switching to the page “Basic Settings” (according to FIG. 1) is located in the area of the quay. Also located in areas of the crane frame are the triangular arrows and the limit switch bars for the crab and lifting motion as well as an indication when the limit switch has been reached, as described above in section 2.1.2 and 2.1.3. On the upper right side, the position of the crab is indicated on the land side crane jib by a red rectangle. The rectangle moves with the movement of the crab over the crane jib and jumps to the crane jib in the upper section of the image, when the triangle reaches the water side of the crane. When returning to the land side, the right rectangle jumps back to the land side jib section.

[0080] The load suspended from the crab is intentionally omitted, since the crane operator obtains better information by looking out of the window of the crane cabin.

[0081] 2.2.2 Park Position

[0082] The touch button “Parkp.” (Park position) is located in the center between the crane legs. When touching this button, the automatic receives the Park position of the crane crab as the target for the next automatic travel.

[0083] 2.2.3 Land Side Targets

[0084] A container symbol indicated with the label “VC-Pos.” (Van Carrier Position) is located on the lower right side of the image. A color change of the grey interior area to light blue indicates that the automatic control has selected the land side target as the next target for the next automatic travel.

[0085] If the function “Intermediate Stop” was activated in the image “Basic Settings” (according to FIG. 1), then the automatic control makes an intermediate stop at the so-called lashing position during travel from the ship side towards the land side, before continuing to the intended target “Van Carrier Position.”

[0086] 2.3 Data Display Field

[0087] The operating data that have to be constantly available to the crane operator are displayed in the lower left quarter of the image (FIG. 2):

[0088] Load weight in t lifting gear 1 (HW 1), lifting gear 2 (HW 2), and sum of the load weight of lifting gear 1+2

[0089] Lifting height—actual values for lifting gear 1+2

[0090] Wind force

[0091] Position of the spreader (in crab direction, i.e. horizontal component) and of the crab itself

[0092] Automatic operation switched on or switched off; if switched on, corresponding operating step of the automatic control

[0093] Active load of container loading/unloading (vertical or horizontal, with or without intermediate stop, loading or unloading) Note: the automatic control independently determines if loading or unloading takes place. If the first container is grasped on the ship after the start of the operation, then an unloading operation occurs; if the container is grasped on the land side, then a loading operation occurs.

[0094] Coordinates of the next target selected by the automatic

[0095] 2.4 Message Bar

[0096] The horizontal message bar in the center of the image informs the crane operator about all states of the crane automatic control: State Display Color Blinking Normal operation Currently running process Yellow No Automatic requires Required action Yellow Yes action from the crane operator Malfunction Indication, possible Orange Yes cause(s), required remedies Warning Indication, possible cause(s), Red Yes possibly required remedies

[0097] Optical signals can be enhanced by announcing text when the computer associated with the touch screen is provided with a sound card.

[0098] Additional details of the invention are described in the claims and the drawings.

[0099] The content of the drawings is self-explanatory to a person skilled in the art (such as a crane operator, a crane project planner). 

1. Operating method for container quay cranes for loading and unloading of container vessels, with a PC with a monitor in a crane driver's cabin, characterized in that the operating method is carried out with a touch screen and a computer, wherein the operating method makes it possible to reach targets of the crane in a fully or partially automatic manner according to parameters transmitted to the computer:
 2. Operating method according to claim 1, characterized in that selected target parameters can be set.
 3. Operating method according to claim 1 or 2, characterized in that the targets that are preset by the automatic control, can be reconstructed on the touch screen before they are reached by the crane.
 4. Operating method according to claim 1, 2 or 3, characterized in that several operating modes are provided, for example for fully automatic travel or for fine-positioning, with switching between the operating modes enabled.
 5. Operating method according to one or more of the preceding claims, characterized in that different loading and unloading modes for the containers can be set.
 6. Operating method according to one or more of the preceding claims, characterized in that an operating mode “Training Operation” can be set.
 7. Operating method according to one or more of the preceding claims, characterized in that an operating mode “Lead” can be set.
 8. Operating method according to one or more of the preceding claims, characterized in that learning functions can be set.
 9. Operating method according to one or more of the preceding claims, characterized in that the actions to be performed by crane operators are displayed.
 10. Container crane operating touch screen, in particular for carrying out the operating method according to one or more of the preceding claims, characterized in that the touch screen has a dark background color, in particular dark blue, and touch fields are indicated in signal colors.
 11. Container crane operating touch screen according to claim 10, characterized in that the touch screen includes symbolically depicted details of a ship and a crane.
 12. Container crane operating touch screen, characterized in that actual target settings, container positions and system states are indicated by color changes.
 13. Container crane operating touch screen according to claims 10, 11 or, 12, characterized in that in addition to the touch fields and the symbolically indicated details of the ship and the crane, there are provided fields for indicating information in text form and in numeric form.
 14. Container crane operating touch screen according to one or more of the claims 10 to 13, characterized in that the touch screen has at least one conspicuous information bar with lettering, in particular an information bar that extends across the touch screen, that indicates the actual operating state or includes operating information.
 15. Container crane operating touch screen according to claim 14, characterized in that the information bar also provides operating instructions to the crane operator before an operating step is initiated.
 16. Container crane operating touch screen according to claim 14 or 15, characterized in that the information bar also displays to the crane operator information about the next required operating step and that the information bar changes its color depending of the type of the displayed contents.
 17. Container crane operating touch screen according to one or more of claims 10 to 16, characterized in that the touch screen can be operated through touching or with a mouse arrow of a PC mouse.
 18. Container crane operating touch screen according to one or more of claims 10 to 17, characterized in that its touch screen program can be programmed and changed in an object-oriented fashion, in particular by using the program Win CC distributed by Siemens AG. 